Unitary Fascia And Gutter

ABSTRACT

A unitary single piece fascia and gutter is extruded from plastic material or a composite and is formed with a relatively flat fascia portion sized to cover the ends of rafters along an edge of a roof. A gutter portion projects upwardly and outwardly from the fascia portion and the gutter portion and fascia portion together bound and define a gutter trough for receiving rainwater and directing the rainwater to a drainage location. The fascia and gutter is installed along an edge of a roof by being positioned along the edge with the fascia portion covering the edge and the gutter portion projecting outwardly from the edge, and securing the fascia and gutter to the edge of the roof with appropriate fasteners.

TECHNICAL FIELD

This disclosure relates generally to roof structures and moreparticularly to fascia and gutters of roof structures.

BACKGROUND

A typical residential gable roof structure has roof decks of apredetermined pitch covered with shingles. A common configuration at thebottom edge portion of the roof structure is an overhang formingsoffits. A vertical fascia board is usually installed at the end of theoverhang to cover ends of roof rafters and to provide a pleasingarchitectural appearance. It also is common for rain gutters to beinstalled along the fascia. The shingles of the roof deck overlap thefascia and partially overhang the gutters so that the gutters collectrainwater from the roof and direct it to downspouts that deliver thewater to a designated location for drainage. In the past, gutters madeof aluminum, copper, plastic, or other material have been fabricatedseparately, either on site or at an off site facility, and installedwith fasteners to the fascia boards of a roof structure. While this isfunctional, it nevertheless has certain inherent problems. For example,the fabrication of custom gutters from metal is time consuming,expensive, and requires a high degree of specialized skill. Theinstallation of the gutters also requires particular skill. Further,once the gutters are installed, they can leak water, especially afteryears of use, and these leaks commonly lead to rotting of the fasciaboards and underlying wooden structures. This condition usually requiresthat the gutters and fascia be removed and replaced with new gutters andfascia. A need thus exists for a fascia and rain gutter system that issimple and efficient to install, that requires a lower degree ofexpertise and skill, that eliminates fascia rotting leaks, and that iseconomic and architecturally pleasing. It is to the provision of such agutter system that the present invention is primarily directed.

SUMMARY

Briefly described, a unitary fascia and gutter is extruded from plasticor a composite material in predetermined lengths. The fascia and gutteris profiled to define a substantially flat fascia portion sized to coverthe rafter ends along the edge of a roof. A gutter portion of the fasciaand gutter is unitarily extruded with the fascia portion and extendsoutwardly and upwardly therefrom so that the gutter and the fasciatogether bound and define a gutter trough. The gutter portion preferablyhas an exterior profile that mimics that of traditional metal gutters,or it may have a unique and different profile if desired. The fascia andgutter is installed along the edge of a roof structure with fastenersthat extend through the fascia portion and into the ends of the roofrafters. When so installed, both the fascia of the roof and the guttersare applied simultaneously. Further, the installation requires asignificantly lower skill level and significantly less time than priorart separate fascia and gutters. No separate fabrication andinstallation of gutters is required and the problems associated withleaking gutters and consequent rotting fascia boards is eliminated. Atcorners, the fascia and gutter can simply be mitered and welded togetherby, for example, heat welding or sonic welding forming a unitary andleak proof corner. These and other features and advantages of thedisclosed fascia and gutter will become more apparent upon review of thedetailed description set forth below when taken in conjunction with theaccompanying drawing figures, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of the edge portion of a roof structureillustrating an installed fascia and gutter according to the presentdisclosure.

FIG. 2 is an enlarged cross section of the fascia and gutter of thisdisclosure illustrating one particular embodiment thereof.

FIG. 3 is a top plan view of the fascia and gutter of this disclosureillustrating two lengths welded together at a corner to form aleak-proof joint.

DETAILED DESCRIPTION

Referring now in more detail to the drawing figures, wherein likenumerals refer to like parts throughout the several views, FIG. 1 is asectional view of a roof structure 11 constructed with a sloped roof 12having rafters 13, a roof deck 14, and shingles 16 overlying the roofdeck. The rafters 13 rest on the top plate of a wall 21 and, in theillustrated structure, ceiling joists 19 define an interior ceiling ofthe structure. The rafters 13 overhang the wall 21 and extend to rafterends 18, which are cut at an angle to define aligned substantiallyvertical ends. The overhanging portion of the rafters and roof 12 definea soffit 22 in a traditional manner. While a traditional gable roof withceiling joists, an overhang, and a soffit have been illustrated in FIG.1, it should be understood that this is not a limitation of theinvention and that the invention may be used with other and varyingtypes of roofs and roof structures. For example, the invention may beused with a roof structure that does not overhang walls to definesoffits but instead is substantially flush with the exterior walls of abuilding.

A unitary fascia and gutter 23 according to the present disclosure issecured to and extends along and covers the ends 18 of the roof rafters13. The fascia and gutter 23 comprises a fascia portion 24, which isformed with a substantially flat configuration and has a widthcorresponding to the width of a traditional fascia board. The thicknessof the fascia portion 24 also may be about the same as that of atraditional fascia board, although it also may be thicker or thinnerdepending upon application dictated requirements. Fasteners 28 aredriven through the fascia portion 24 and into the ends 18 of the rafters13 to secure the fascia and gutter in place as shown. The fasteners maybe nails, screws, staples, or any other fastener appropriate forsecuring the fascia portion to the rafter ends 18. When secured alongthe ends of the rafters as shown, the fascia portion 24 mimics theappearance of a traditional fascia board that otherwise might beattached to define the fascia of the roof edge.

A gutter portion 26 of the fascia and gutter 23 is formed unitarily withthe fascia portion and extends outwardly and upwardly therefrom. Morespecifically, the gutter portion 26 extends outwardly from near thebottom edge of the fascia portion 24 and then upwardly to a lip 33. Theexterior profile of the gutter portion 26 may be shaped to mimic theprofile of a traditional metal gutter as illustrated in FIG. 1, or,alternatively, it may be formed with other and distinct shapes asdesired or needed. In any event, the gutter portion 26 in conjunctionwith the fascia portion 24 bounds and defines a gutter trough 27 shapedto contain rainwater and direct it to a drainage location. The shingles16 of the roof 12 preferably overhang the top edge of the fascia portion18 as illustrated in FIG. 1 so that rainwater flowing down the roof isdirected into the gutter trough 27, where it is contained in the trough27 by the fascia portion defining the back of the trough and the gutterportion defining the front of the trough. One or more downspouts 29 maybe secured to a corresponding opening formed through the bottom of thegutter trough to receive rainwater from within the trough and direct itdownwardly to be drained away from the building.

FIG. 2 is a cross sectional view of one possible embodiment of thefascia and gutter of this disclosure. As mentioned above, the unitaryfascia and gutter 23 is formed with a fascia portion 24 and a gutterportion 26. More specifically, the fascia and gutter 23 preferably isformed by extrusion of an material appropriate to lend strength,durability, and appearance to the unitary fascia and gutter. Suchmaterials might include, for example, a plastic material such aspolyvinylchloride (PVC), a composite material such as a plastic withorganic or inorganic fillers, or another appropriate material. In theexemplary embodiment of FIG. 2, the fascia and gutter 23 is extruded ofa plastic material with a relatively less dense foamed plastic core 31surrounded by a relatively more dense plastic skin 32. Thisconfiguration is lightweight, makes efficient use of materials, andprovides for a durable exterior surface that mimics the look oftraditional metal gutters. Further, the fascia and gutter can beextruded of plastics having a variety of colors to match variousarchitectures and decoration schemes, and, unlike metal gutters, thecolor is indelible and scratch proof.

The unitary fascia and gutter of this disclosure offers additionaladvantages when two lengths are joined at a corner of the roof, wheretraditional metal gutters sometimes are joined in an unsightly manner orhave a tendency to leak. FIG. 3 illustrates first and second lengths ofthe fascia and gutter of this disclosure meeting at a right angle andjoined together as they would be at a corner of a roof. Morespecifically, each length is mitered at its end, in this case atforty-five degrees. The mitered ends are then thermally welded togetheralong joint 34 to form a watertight, strong, and unitary connectionbetween the lengths of fascia and gutter. The ends may be welded in anyacceptable manner such as, for instance, with a heated welding plate,plastic welding rods, a sonic welder, or the like. In any event, thejoint between the two meeting lengths is superior to traditional cornerjoints where metal gutters are joined because it is stronger andsubstantially leak proof and the gutter trough 27 extends unobstructedaround the corner of the roof.

The invention has been described herein in terms of preferredembodiments and methodologies that represent the best mode known to theinventor of carrying out the invention. However, numerous modifications,additions, and deletions might be made to the illustrated embodimentswithin the scope of the invention. For example, the particular shape ofthe gutter portion and/or the fascia portion can be different from thatillustrated in the preferred embodiments. Further, the fascia and guttermay be formed by methods other than extrusion and may be fabricated ofany material with the appropriate strength and durability to withstandstresses encountered in use. In addition, the fascia and gutter may befabricated with the gutter portion extending at a slight angle withrespect to the fascia portion so that, when installed, water will tendto run toward one end of the gutter portion for draining out through adownspout. In fact, lengths of the fascia and gutter may be formed withgutter portions that slope at opposite angles or that are higher orlower on the fascia portion so that long runs of fascia and gutter canbe connected end to end while maintaining the slope of the gutterportion or to provide a slope in either direction. These and othermodifications and additions might well be made to the illustratedembodiments without departing from the spirit and scope of the inventionas set forth in the claims.

1. A roof structure comprising: a roof deck supported by rafters, therafters extending to substantially vertical ends along an edge of theroof structure; shingles covering the roof deck; a fascia spanning thevertical ends of the rafters along the edge of the roof structure; and agutter projecting outwardly and upwardly from the fascia to define thefront wall of a trough; the fascia defining a rear wall of the troughsuch that the gutter and fascia together bound and define the trough andcooperate to collect and direct rainwater to a drainage location.
 2. Aroof structure as claimed in claim 1 and wherein the fascia and thegutter are formed together as a unitary structure.
 3. A roof structureas claimed in claim 1 and wherein both the fascia and the gutter areformed of the same material.
 4. A roof structure as claimed in claim 3and wherein the fascia and the gutter are formed of a plastic material.5. A roof structure as claimed in claim 4 and wherein the plasticmaterial comprises PVC.
 6. A roof structure as claimed in claim 4 andwherein the plastic material comprises a composite material includingplastic and a filler.
 7. A roof structure as claimed in claim 4 andwherein the plastic material has a relatively less dense plastic coreencased in a relatively more dense plastic skin.
 8. A roof structure asclaimed in claim 4 and wherein the fascia and the gutter are formed as aunitary structure.
 9. A unitary molded fascia and gutter comprising afascia portion sized and shaped to span and cover the ends of raftersalong an edge of a roof and a gutter portion projecting outwardly andupwardly from the fascia portion to form a trough sized to receive,contain, and direct rainwater, the trough being bounded and defined bythe gutter portion of the fascia and gutter and the fascia portion ofthe fascia and gutter.
 10. The fascia and gutter of claim 9 and whereinthe fascia and gutter are molded of a plastic material.
 11. The fasciaand gutter of claim 10 and wherein the plastic material comprises PVC.12. The fascia and gutter of claim 11 and wherein the fascia and gutterhave a relatively less dense core encased by a relatively more denseskin.
 13. The fascia and gutter of claim 9 and wherein the fascia andgutter are molded of a composite material.
 14. The fascia and gutter ofclaim 9 and wherein the fascia and gutter are molded with an extrusionprocess.
 15. The fascia and gutter of claim 9 and wherein the gutterportion extends at a predetermined angle relative to the fascia portionto define a grade for directing rainwater downhill when the fascia andgutter are installed.
 16. A method of installing a fascia and gutteralong an edge of a roof structure, the method comprising the steps of:(a) extruding a unitary fascia and gutter comprising a relatively flatfascia portion and a gutter portion projecting outwardly and upwardlyfrom the fascia portion to define, with the fascia portion, a guttertrough; (b) positioning the unitary fascia and gutter along the edge ofthe roof structure with the gutter trough at least partially underlyingthe edges of shingles on the roof structure; and (c) securing theunitary fascia and gutter to the edge of the roof structure.
 17. Themethod of claim 16 and where in step (a) the fascia and gutter areextruded from a plastic material.
 18. The method of claim 17 and whereinthe plastic material comprises PVC.
 19. The method of claim 16 andwherein in step (a) the fascia and gutter are extruded from a compositematerial.
 20. A unitary structure formed to define a relatively flatfascia portion and a gutter portion projecting outwardly from a face ofthe fascia portion and wherein the fascia portion and the gutter portiontogether form a gutter for receiving rainwater and directing therainwater to a drainage location.